PLEASE READ: Enterprise Prop Help; Enlisting advice from anyone!

[thegreatgalling]

Hey folks,

I would love some advice on how I can build the elusive hyperspanner from Star Trek Enterprise. I am really at a loss on how to even begin. I have had trouble finding a source for hexagonal wood, and a steel piece could run up to $100 a pop to be cut the proper shape. I am aware there is ONE thread about a spanner, but the picture link is outdated and doesn't appear (so I am not even sure if its discussing the right thing). Please note that pouring resin is out of my skill level as of yet.

This is the spanner (http://memory-alpha.org/en/wiki/Hyperspanner)

I do not need it to open like the one shown. Apparently, there were a few hero ones and a few made of soft foam. (Particularly the one that is used a weapon in one episode).

Any guidance would be appreciated. Anything that can be adapted to look like this? Anyone who can make some for me for a fee? Anyone do this before?

I am on my way to making a full replica Engineering case. After months of looking, I secured a Hardigg box close enough in dimensions.

And my case:

Here is some progress on the tools, albeit before the ton of work they need.

And some found items (or close enough):

Reference pics:

As this is really more of a "background" prop replica, I am not going for amazing accuracy. I appreciate any help in advance.

I should mention that there are two different sizes of spanner in the case. The 12" ones (the three on the second level) and the one shorter one on the top level.

Joe

 

[thegreatgalling]

I came across this tool which some say looks like a hyperspanner.

http://www.markstechnologynews.com/...ustable-wrench-looks-like-a-hyperspanner.html

One option I have been cosidering is starting from a simple pool thermometer:

http://www.amazon.com/Generic-4RH17-Jumbo-Pool-Thermometer/dp/B000OMZB1M

 

[Rebelscum]

Do you have a dimension across the flats on the hexagon rod?

 

[thegreatgalling]

From It's a Wrap:

"The foam tray in the case pulls out by way of fabric tabs at the edges to reveal a trio of spanners which recur in multiple episodes. The spanners are hexagonal in shape measuring approx. 12 X 1.5 X 1.5 X 1.5 inches and one is fashioned from machined metal with multi-colored accents and rubber faux buttons, a second matches and is fashioned from soft foam rubber while the third is made from sturdy molded rubber."

 

[phez]

I would be willing to bet they just took some Aluminum Hex Bar and machined some groves into it.

Here is a link to the stuff.

http://www.onlinemetals.com/merchant.cfm?id=744&step=2&top_cat=60

 

[thegreatgalling]

That is very helpful, thanks!

 

[thegreatgalling]

I was able to find a source for 1-1/2 inch diameter aluminum hex bars cut to any length. Thanks a million. For some reason my mind went straight to steel without considering aluminum, the lighter, cheaper alternative! :confused I also picked up the right 3M bumpers.

With that said, we can add machining metal to that list of things outside my grasp. Does the remaining detail (the thicker indentations) look like something store bought that I can attach to the hex bar? I know I can just stick some pvc pipe in between some LARGE bolts, but I was hoping it resembled something already out there.

Worst case scenario, I can live with a 12" hex bar with some foil tape representing the indentations, but I would like to try to make it more true to form if I can.

If you have any further suggestions, please let me know.

Joe

 

[Vaderman]

I'll bet it was a level.

Then it was cast and resin copies made and greeblies added on, pieces cut for opening, etc.

 

[thegreatgalling]

Like a line level? I have to see if I can find something similar in shape.

 

[thegreatgalling]

Does anyone have any machining sources? After looking at the pics again, I think Phez is exactly right as the piece appears to be a simple aluminum hex bar with six grooves carved into it, three on one end at about 2/16ths of an inch, and three on the other end at about a quarter of an inch? Any help would be appreciated.

Joe

 

[Maelstrom]

The buttons look like rubber bump-stops with numbers printed on them.

 

[lonepigeon]

If machining is out of the question you could just put a bunch of hex nuts on a threaded rod. Alternate hex nut, round spacer, hex nut on the ends and either the solid bar, hex tubing, or hex standoffs for the main body.

http://www.mcmaster.com/#hex-standoffs/=39i16k

Edit - I didn't realize how big these things were. Finding hardware that size would be tough.

 

[thegreatgalling]

Thanks for the info, it is tough that they are big but I am going to take a look, I really appreciate it.

 

[thegreatgalling]

Still having trouble finding a company that performs custom machining. The ideal situation would be a company that sells 1.5" by 12" aluminum hex bar and did the machining on site to specifications.

 

[Rebelscum]

Still having trouble finding a company that performs custom machining. The ideal situation would be a company that sells 1.5" by 12" aluminum hex bar and did the machining on site to specifications.

Was that 1.5" across the flats or points?

 

[thegreatgalling]

Was that 1.5" across the flats or points?

To be honest, I don't know for sure. Any dimensions I could muster for this comes from It's a Wrap auction house who put up the case a few years ago.

You'd prob. know better, but it seems to me that Aluminum hex bar is usually presented as a measurement from the flats? While I wouldn't trust It's a Wrap to know that, I would prob bet the prop matched the standard.

 

[Rebelscum]

To be honest, I don't know for sure. Any dimensions I could muster for this comes from It's a Wrap auction house who put up the case a few years ago.

You'd prob. know better, but it seems to me that Aluminum hex bar is usually presented as a measurement from the flats? While I wouldn't trust It's a Wrap to know that, I would prob bet the prop matched the standard.

I checked on hex aluminum material and it doesn't come larger than 1" across the flats.

 

[cheech9898]

I checked on hex aluminum material and it doesn't come larger than 1" across the flats.

Many places like Speedy Metals, Online Metals and Metals Depot don't stock over 1 inch hex, but it is available.

McMaster-Carr carries up to 2 inch aluminum hex. 1-1/2 inch is available in 12 inch, 36 inch and 6ft lengths in 2011, 2024, and 6061 alloy. 6061 is the cheapest, part #89845K561 for a 12 inch length.

 

[Great_Bizarro]

Model it out of clay then cast it from resin and add the bumpers. You could even make a hero one doing it that way. You then only need 1 master and can cast as many as you want. Paint silver or add alum. powder to the resin for a great looking prop.

 

[Rebelscum]

Many places like Speedy Metals, Online Metals and Metals Depot don't stock over 1 inch hex, but it is available.

McMaster-Carr carries up to 2 inch aluminum hex. 1-1/2 inch is available in 12 inch, 36 inch and 6ft lengths in 2011, 2024, and 6061 alloy. 6061 is the cheapest, part #89845K561 for a 12 inch length.

Thanks. I should have been more specific. My local supplier doesn't carry it over 1".